Electric welder



Allg. 31, 1954 N Q CLARK 2,688,065

l ELECTRIC WELDER Filed sept. 11, 1951 4 sheets-sheet 1 33 L35 h":vvVm/'Tok F. 40 34 /VfLjo/V 0. 60410( 4 Sheets-Sheet 2 Filed sept. 11, 1951 0 6 il z m p. a 8 O O m 4 9 f 5/ VQ w f/ 7 1 9 W. f 4 l l.- 4 x n M 0 r s W r a mw Z 0 if.; 2 7 e z v I a n H 4 T 6 6 3 4 wwmw we W4 1 ihk L f 4. M. En n w w s a 6 5 6 H 3 ug. 3l, 1954 N, o, CLARK 2,688,065

ELECTRIC WELDER Filed Sept. 11 1951 4 Sheets-Sheet 3 IN VEN TOR. Ma my 0. L 1f/f 54 BY M Aus- 31, 1954 N. o. CLARK 2,688,065

ELECTRIC WELDER Filed Sept. ll, 1951 4 Sheets-Sheet 4 Patented Aug. 31, 1954 ITED STATS PATENT OFFICE 6 Claims.

This invention relates generally to electric welding devices and particularly to welders for effecting uniform welds 0n relatively small-dimensional articles manufactured on a quantity production basis.

Electric welding devices are well-known in the art but usually are not intended for producing exactly uniform welds. As a matter of fact, with most of such devices welding uniformity is nigh impossible of achievement due mostly to the ever changing difference in impact intensity between the contacting electrodes which are usually of cumbersome construction and are affected by friction, stiffness of conductors or other obstacles during their movement toward or from one another.

The present invention contemplates a Welder construction wherein stationary and mobile electrodes are employed, and wherein the operation of the mobile electrode is unimpaired by either the operating mechanism for moving it or by any other causes which would impede the movement of the mobile electrode. In order to produce consistently uniform welds, especially when welding relatively small articles, or even larger art'- cles of similar or diiferent materials, the prime requirement seems to be the uniformity of interengagement between the electrodes, the uniformity of impact upon the work to be welded and the correct timing of the passage of the Welding current through the electrode at the moment the Weld is to be effected.

Obviously it must be assumed that the areas of the articles to be welded are clean, and when mass production is to be effected, the shape, size and thickness of the articles to be welded must be consistently uniform in order to produce substantially identical welds with a given set-up and adjustment of the Welder.

Added to the aforesaid requirements the temN perature necessary for effecting uniform welds of such articles must also be consistently uniform. Any heat losses which may occur during each Welding operation preferably should form but a very small part of the total welding heat required, and such losses should also be held as constant as possible. To achieve the correct weldirrT heat required, the contact resistance at the point of the weld should be consistently uniform. There exists a definite relation between the required welding heat and the heat losses during the welding operation. Such heat losses are due to many causes, for instance, the heat dissipation over the surfacesto be welded, heat losses due to conductionL and radiation andl also due to convection.

All of the heat losses are in direct proportion to the time required foreffecting a weld. Therefore the shorter the welding period, the smaller will be the heat losses. Consequently the closer the welding period approaches zero time, the lesser will be the heat losses.

Difficulty is particularly encountered in welding small parts to larger parts, and the above axiom of shortening the welding period becomes especially applicable, since when the weld is attempted slowly, the larger part will dissipate the heat and may never reach the welding tempe'raf ture, while the small part may melt. it is essential therefore to deliver relatively intense heat during as short a time as possible, which is effected by passing a current of high intensity through the point of weld in as short a time as possible. In heretofore used welding devices known as condenser Welders, inductances or stepdown transformers were employed in the discharge circuit. They slow down the time of discharge and therefore increase the time of the welding period. The present invention contemplates the elimination of transformers from the discharge circuit for condenser welders. Furthermore, the present invention contemplates a condenser discharge circuit of as little interior re sistance as possible so that the resistance of the circuit forms but a small percentage of the contact resistance at the point of the weld.

When it becomes necessary to weld small parts to larger parts it is desirable to slow down thev welding time somewhat in order to allow the larger part to reach welding temperature by conduction and by a slight swaging action. To meet such contingency the present invention contemplates the employment in the condenser discharge circuit of a plurality of condensers, of which at least one condenser may loe charged at a cornparatively high voltage, whereupon the high voltage charge is transferred to a condenser of a larger capacity prior to passing the charge through the welding electrodes.

in mas-s production the time element is of utmost consideration. rI'he time required to charge a condenser limits the rate of producing welds. The present invention contemplates overcoming that diiculty by the employment in the condenser discharge circuit or" a plurality of condensers so that while one ci the condensers is being charged, another condenser is being discharged through the electrode termini.

in order to enhance the work capacity of .velders is essential to render them adjustable for dierent types of work to be handled by the welder. It is necessary therefore when smaller or larger articles are to be welded, to correspondingly regulate the current intensity which is to pass through the weld. For that reason the present invention contemplates the provision of an adjustable power supply, fed from a constant source of energy for delivery into the discharge circuit of the required direct current voltage to the condenser. Assuming that a Welder receives power from an alternating current line, its voltage may be regulated by a variable transformer or potentiometer from which the current adjusted to the required voltage is passed through a limiting choke and a half-wave rectiiier. With the thus produced direct current the condenser is charged. Obviously the conversion from A. C. to D. C. voltage may be achieved by other means than a half-wave rectifier, such as electronic or other rectifying device well known in the art.

The heat developed at the point of the weld is a function of contact resistance and varies with the physical and other properties of the material to be welded and with the properties of the electrodes, as well as with the pressure eX- erted by the electrodes against the work piece and furthermore with the shape and size of the work piece. Therefore in order to obtain consecutive uniformity in welds of like articles, it is essential that the contact resistance be maintained uniformly. In heretofore used welding devices very little attention was paid to the amount of pressure developed between the electrodes during welding operations. That pressure, as stated, may greatly vary due to friction losses and other factors, such as temperature changes, lubrication, etc. .As a result, welders wherein pressure between electrodes varies are limited to welding relatively large work pieces. When small parts are to be welded, variations in pressure between the electrodes would preclude uniformity in welds unsuitable for quantity we1ding production.

The present invention contemplates to overcome the faults of heretofore welders, especially as to the variability of pressure during welding operations by the provision of means for controlling the movement of and the impact by the mobile electrode in respect to the stationary electrode and by the employment of other means for effecting uniform pressure between the electrodes, both of which control means are designed to render the mobile electrode independent of any frictional influences or other impedances in its operation.

As stated, an essential feature in a welder to produce uniform welds, is the timing of the pacsage of current through the electrodes. The present invention contemplates provisions for exactly timing the passage of current through the electrodes at the very instant the electrodes contact, the current being discontinued prior to the separation or the electrodes.

The principal objects of this invention therefore are the provision of an electric Welder in which is employed a transformerless discharge circuit and in which discharge circuit are included regulating means for adjusting the current voltage, a resistance element and a halfwave rectier in conjunction with at least one or a plurality of condensers chargeable by the current iiowing from the rectiiier, and wherein means are provided for exactly timing the passage of a discharge from the condenser through the welding termini of the electrodes at the time of their contact with one another, and the stoppage of the current prior to the separation of the electrodes, and wherein means are provided for eiecting uniform contact pressure between the electrodes to effect uniformity in welds of relatively uniform parts to be welded.

A further object of this invention is the provision in the above transformerlesg discharge circuit of a welder, of a plurality of condensers wherein one of the condensers is chargeable with a relatively high voltage and from which condenser the charge is transferred to a condenser of a much larger capacity prior to passing the charge through the electrodes.

Another object of this invention is the provision in a Welder of a transformerless discharge circuit wherein are employed several condensers, and wherein means are provided, such as auX- iliary switch means, for transferring the charge from one condenser to another condenser prior to delivering the transferred charge through the contacting termini of the electrodes.

A still further object of this invention is the provision in a discharge circuit of an electric Welder, of a plurality of condensers and suitn able auxiliary switch means to permit the charging of one condenser while the charge of the other condenser is being discharged through the electrodes.

The foregoing and still other important objects and additional advantages of the present invention will become more readily apparent from the ensuing description in conjunction with the accompanying drawings, wherein:

Fig. 1 represents a diagrammatical side elevation of an electric Welder in accordance with the present invention;

Fig. 2 is a top View thereof;

Fig. 3 is an elevation similar to that oi Fig. 1 but seen from the opposite side of the Welder;

Fig. 4 is an end View of the Welder seen in the direction of arrows ffl- 4 indicated in Fig. 3;

Fig. 5 is an end View seen in the direction of arrows 5-5 of Fig. 3;

Fig. 6` is a section approximately along line liof Fig. 3 with the Welder operating yoke shown in two positions;

Fig. 7 is a bottom view of the yoke;

Fig. 8 is an enlarged fragmental detail view of the switch timing mechanism, partly in section, shown in its normal position and seen in the direction of arrows 8 8 indicated in Fig, 6;

Fig. 9 is a similar enlarged partial detail View of the mechanism in an intermedia-te position;

Fig. 10 is a similar enlarged detail view of the mechanism in still another position;

Fig. 11 is a partial section taken along line H-li of Fig. 1;

Fig. 12 is an enlarged cross section through the spring-loaded stop of the Welder taken along line [2-1'2 of Fig, 3;

Fig. 13 is a partial section taken along line lil-I3 of Fig. 3 through the work support of the stationary electrode;

Fig. 14 is a partial section taken approximately along line Id-I of Fig. 3;

Fig. 15 is a partial sectional view taken along line i5-l5 of Fig. 4;

Fig. 16 is an electric diagram showing a discharge circuit with a single condenser as employed in the welder seen in Figs. 1 to 5;

Fig. 17 is a similar diagram showing a discharge circuit employing two sets of condensers and auxiliary switch means;

Fig. 18 is a diagram of the discharge circuit employing three different condensers and auxiliary switch means for alternately connectingV them; and

Fig. 19 is a diagram of the discharge circuit similar to that shown in Fig.- 16; butin which two'sets of Velectrodes are employed and two condensers, one for each electrode set, and. auxiliary switch means for the condensers;

The drawings of the presentdevice are held in` a more or less diagrammatical form and' are primarily intended to facilitate the explanation of the different features of the devicerather than its structure.l The device is supported'by a platform'rlwhich is intended'to represent any suitable base upon which the device'can be mounted. Extending from platform IE! is a supporting column' Il from which extends stationary electrode l2beyond the edge of the platform. Electrode I2' preferably constitutes a xed arm, at the end of which is adjustably mounted a work support i3, which'latter is shownl clamped between the split endof the electrode and-held in position by means of bolt I4. In electrode l2 there is also adjustably mounted a spring-loaded stop l5, shown in` greater detail in Fig. l2, the structure and function of which will be explained presently.

In supporting column l l there is pivotally sup ported at Ita mobile electrode Il, the latter be ing composed of a rigid portion IB and a resilient portion I9 extending from the latter and comprising a cantilever spring, at the end of which is located the contact terminus 2G of the mobile electrode just opposite Contact terminus 2i of work support |3,` see Figs. 1 and 3. At the lower surface of rigid portion i8 ci the mobile electrode there is provided an insulation plate 22 which serves as abutment for adjustable stop l5` and electrically separates the two electrodes.

Referring again to Fig. 12, it will' be observed that in stationary electrode l2 l is provided a threadedv passage for the reception of an externally threaded tubular element 23 which terminates in a knurled head 24 through which projects a pin 25 supported by a spring 2t, the latters tension being adjustable by means of a set screw 2l projecting from bottom lock nut 28 for tubularelement 23. In its locking position -nut E3 bears against the bottom surface of electrode l2. Another lock ynut 29 engages element 23 and bears in its locking position :against the top surface of electrode I2.'

The rigid portion i 8 of electrode It' operates within guides to prevent any side-wise deiiections vof mobile electrode contact terminus i253 relative work support terminus 2l of the stationary electrode. Supported by rigid portion I3 `of the mobile electrode is a block structure 3i from which extends a support pin 32 for spring 3.3, the lower end of which engages a pin 34 extending from lever 35 which is pivoted at 35 in the column Il.

As stated, mobile electrode Il is pivoted at it in the column and on the same pivot are operatively mounted side guide arms 36 movable simultaneously with electrode Il, the rigid portion I3 ofthe electrode being supported by a connecting pin 3l passing through the guide arms 33, as clearly seen in Figs. 1, 2 and le. At the free ends of the guide arms are mounted aligned, individq e ual pins 38, see Figs. 1and 6, with which are operatively associated the two legs of the electrode operating yoke 39. One of the yoke legs 40 is shorter than its other leg lll, which latter extends above block structure 3 I, as may be clearly observed from Fig. 6; Pin 34 for spring 33 CTI passes from lever 35 through shorter leg Alllof` electrode operating yoke 39. The'yoke is intended for foot operation by a chain or other suitable means.

In block structure 3l there is pivotally lodged.'

a pin 42 (see Fig. 6). Fixedly associated with that at the right of the iigure is a .lever element d3, shown in side view in Fig. 1 and in end view in Figs. e and 5 and partly in section in Fig. 15. From the enlarged hub portion 43 or the element extends a stop pin 43 for engagement with a corresponding stop pin 3| p jectng from block structure 3l, see Fig. 15. A string i4 normally urges lever element 43 toward column il.

At the opposite or left end of pin 42 thereis secured a cam il which is normally urged by spring engaging lever element 43 to'its normal position indicated in Fig. 8, whereby mercury switch il@ is held at its normal, circuit` breaking position. By consulting Figs. 8, 9 and l0 it will be observed that cam 4l has two'distinct cam surfaces 48 and 49 which converge a point En.

Referring to Fig. 6, it will be seen that the denser which instrumentalities form parts of the discharge circuit for the Welder.

En the four diagrams shown in Figs. 16 to 19, plugs represent the sources of electric energy which may be of either direct or alternating current but being assumed, for the purpose of explaining the diagrams, as an alternating current source. Directly connected to plugs 59 are either adjustable transformers or potentiometers 60 provided with movable contacts 6l for varying the voltage required. Contacts 5i are connected with choke coils or resistances B2' and the latter are connected with half-wave rcctiiiers 63. Numerals and in the diagrams correspond to numerals and 56 in Figs. 1 to 5.

The circuit diagram of Fig. 16 corresponds toi the discharge circuit arrangement employed in the Welder illustrated in Figs. l to 5, in which is also shown a single condenser 58, a mercury switch et, a stationary electrode l2 and a mobile electrode il.

The diagram in Fig. 17 essentially is the same that of Fig. 16 except that instead of single condenser 5S there are shown a low capacity condenser iifl twin condensers 65, the latter serving,r as a large capacity condenser. There will beY also observed auxiliary switch means which adapted for i'lrst connecting condenser 84T with rectifier (i3 to permit charging of the con-- at high voltage, whereupon the auxiliaryl switch means are thrown to connect condenser" (it with twin condenser-s 65 to distribute the charge through a larger capacity prior tobeing discharged through the contacting electrodes by way or mercury switch 45.

In the diagramv disclosed in Fig. 18 there are employed three condensers -6'l, 68 and` 69 anda..

Also xedly mounted at theright-hand end of pin l2 is a spring clip 45 for engaging and supporting a mercury switclrllii.v

, a pin 5i about which pivots a travelingV modined auxiliary switch structure lil. Two leads ll and l2 extend from rectifier 63 and terminate, respectively, in contact points li and l2'. From condenser l passes a lead to a contact point 6l', and a similar contact point G3 forms the terminus of a lead from condenser ou, and another contact point 69 forms the terminus of lead i3 from condenser Se, and still another lead 'lli from condenser t9 extends to contact point 'ai-'i'. Auxiliary switch "iii, which is of course shown in a most simple and purely diagrammatical form, comprises a dielectric connecting member 'l5 from which extend individual switch blade structures 'i6 and 'il'. Each of these bla-de structures have at least one curved terminus la and "ll", respectively. In the position of the auxiliary switch shown, the rectifier is connected by lead "li and its contact point ll with switch blade structure 76, the latter engaging contact 6l at the end of the lead from condenser i'l. At that switch position condenser iii' is being charged. At the same time switch blade structure 'Il establishes connections between previously charged condenser 53 and condenser 5t, which two condensers then serve in the same capacity as double condensers @E shown in Fig. l'. In other words, the charge from condenser 68 is caused to be distributed over a larger capacity by the inclusion of condenser S9 prior to passing the charge by Way of mercury switch d'5 through the electrodes. When auxiliary switch stucture l@ is moved to the right, charged condenser di' is connected with auxiliary condenser 69 to again distribute the charge over a larger capacity, while condenser 58 is being charged in that contact l2 from lead "52 extending from the rectiiier is connected with switch blade structure il, and the upper looped portion ll of that switch structure will engage contact i555' oi the lead from condenser e8. Obviously, contact point 5S is disconnected from the switch blade structure so that auxiliary condenser 59 becomes disconnected irorn condenser @iii during the time the latter is being charged.

The diagram shown in Fig. 19 indicates the employment of two sets oi welding electrodes in conjunction with two sets of mercury switches and two sets of condensers, indicated at ld and lil, and the employment of an auxiliary switch device te. The latter is adapted to connect either one of the condensers with rectiiier 52 for alternately charging it. The procedure is such that while one of the condensers is being charged, the other is being discharged between one set of electrodes and while the discharged condenser is being charged, the charged condenser is discharging through the other set of electrodes. Thus time required for charging the condensers is being saved by the use or" two Welder sets.

Operation of the welder The present device is particularly adapted to effect the delivery of electric energy of the required intensity through the interconnected electrode termini at the correct moment and for the correct duration, say at the very instant the electrodes become engaged with one another.'

8. electrode il, the latters rigid portion I8, normally supported by spring-loaded pin 25, will come to rest against head 24 of the stop. At that position resilient cantilever extension i9 of the electrode is brought under certain tension so that its contact terminus 20 positively engages the work piece resting upon terminus 2| of adjustable work support I3. The force of impact by contact terminus 2) upon the work piece during successive welding operations is maintained uniformly due to the iact that resilient extension is is placed under the same tension as it always travels the same distance in engaging a work piece of the same thickness. ln other words extension le is never subjected to an over-strain. Therefore no matter how harshly or how lightly yoke 39 is operated to actuate electrode I'i, by way of a pedal or other suitable means, the contact engagement of the work piece by the electrode termini always will be the same, irrespective of mechanical friction or stiffness of the electric leads by which the electrodes are connected.

For the purpose of properly timing the passage of current through the electrode termini there is employed mercury switch it and the required mechanism for operating the switch to close the circuit at the moment the work piece becomes forcibly held between the electrode termini, and to immediately break the circuit when the weld is made and prior to the release of the welded work piece by the electrode termini. That switch-operating mechanism consists of the previously described cam di and traveling pawl 52. The normal circuit-breaking position of switch i6 and the corresponding position of cam lll is shown in Fig. 8. When yoke 39 is operated in downward direction, roller 53 of pawl 52 engages the doubly curved cam surface it and causes the cam to momentarily assume the position shown in Fig. 9 as roller `53 passes over the hump of cam surfaces lit. At that position of the cam, switch 4b assumes its circuit-closing position, thus causing an electric charge to pass through the work-piece held between the electrode termini.

As the pawl progresses in its downward movement, roller 53 approaches and finally passes the apex or converging point 5@ of the two cam surfaces 4S and 45, thus releasing cam lll', the latter then reassuming its normal position, being brought to that position by the action of spring M engaging lever element @33 and urging it to turn in anticlockwise direction; consequently switch i6 also reassumes its normal, circuit-breaking position. As now yoke 39 is released to travel upward, roller 53 of pawl 52 willy engage and travel over cam surface de and will roll over the hub of the cam as it reverts to its normal position, shown in Fig. 8, by the action of spring El supported in plate 55.

In order to hold cam lll in its normal position, shown in Fig. 8, and against the tension of spring lliengaging lever element dt, pin 53, extending from the hub of that lever element, will arrest the latters movement as it engages pin 3l projecting from block structure 3i, see Fig. l5. The upward movement of operating yoke 39 is eiiected by spring 33 held under tension between pin 32, extending from block structure 3 i, and pin Sil projecting from pivoted lever 35.

The device shown in the drawings and described in the foregoing is primarily intended for the welding of like, relatively small and lightbodied parts. Obviously the present invention is not intended to be limited to just such specific application and its principle can be readily employed in Welding large articles of any desired structural or physical properties diierent from those indicated herein, provided appropriate changes or modications in the structure of the device are made to meet such requirements, such obvious changes or modifications being deemed to reside within the broad scope of the present invention, as dened in the annexed claims.

What is claimed as new is:

l. In an electric welder, a stationary, rigid electrode having as its terminus an adjustable work support, a mobile electrode movable relative to the stationary electrode and comprising a rigid portion and a resilient blade extension, the latter forming a ilexible contact terminus of the mobile electrode and being adapted for cooperation with said work support, an adjustable spring-loaded stop for the rigid portion or" the mobile electrode mounted in the stationary electrode, said stop being adapted to normally keep said contact terminus spaced from said work support; means for moving the mobile electrode toward the stationary electrode, thereby eiiecting a tensional engagement of the work support by the resilient extension; an electric power source, a transformerless discharge circuit, including a directly dischargeable capacitance, supplied by said source; an electric switch operative simultaneously with the mobile electrode and controlling the timing of the discharge of electric energy from said capacitance through the termini of the electrodes during their interengagement and prior to their separation, and switch actuating means for effecting the movement of the switch from its normal, circuit-opening to its circuit-closing position and back to its normal circuit-opening position.

2. In an electric welder as in claim 1, said switch actuating means comprising a springloaded cam operatively associated with the switch and being swingable with the latter about a joined pivot, said cam having two converging cam surfaces, a spring-loaded traveling pawl movable bodily relative to the cam body and adapted to successively engage rst one and then the other cam surface during its travels rst in one and then in an opposite direction as the mobile electrode is moved rst toward and then away from the stationary electrode, whereby said cam is iirst swung from its normal position to a second, temporary position, and is kept in that position while the pawl progresses in that one direction over' that one cam surface toward the converging point of the two cam surfaces, the pawl upon passing that converging point releasing the cam, the latter reassuming its normal position while the pawl commences its travel in that opposite direction, the pawl then engaging and moving along the other cam surface to its starting position in readiness for its next operating cycle.

3. In an electric welder as in claim 1, said capacitance comprising at least two condensers forming parts of said discharge circuit and being adapted to become alternately charged by said source and to be alternately discharged by way of said switch through 'the interengaged termini of the electrodes; and auxiliary switch means for facilitating the alternate charging of the condensers and their alternate discharge by way of said electric switch.

4. In an electric welder as in claim 1, said capacitance comprising at least two condensers of relatively low and relatively high capacities forming parts of said discharge circuit, auxiliary switch means for rst connecting the low capacity condenser with the source for charging it and then with the high capacity condenser for discharging it thereinto prior to the passage of electric energy through the interengaged electrode termini by way of said electric switch.

5. In an electric Welder as in claim 1, said capacitance comprising at least three condensers forming parts of said discharge circuit, and auxiliary switch means for facilitating an alternate charging of one condenser and the simultaneous discharge of two connected condensers by way oi said electric switch through the interengaged electrode termini.

6. In an electric Welder as in claim 1, said capacitance comprising at least three condensers forming parts of said discharge circuit, and auxiliary switch means for facilitating an alternate charging of one condenser and the simultaneous discharge of two connected condensers by way of said electric switch through the interengaged electrode termini, said auxiliary switch means being adapted to rst connect one condenser with the source for charging it and then to connect the charged condenser with another condenser to distribute the charge over larger capacity prior to passing the charge through the interengaged electrode termini via said electric switch.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 1,299,150 Dyer Apr. 1, 1919 1,489,093 Mershon Apr. 1, 1924 1,863,850 Holloway June 21, 1932 2,275,635 Lindenblad Mar. 10, 1942 2,319,385 Calvert May 18, 1943 2,413,391 Usselman Dec. 31, 1946 2,432,292 Deal Dec. 9, 1947 2,452,009 Woodward Oct. 19, 1948 2,454,338 Pityo Nov. 23, 1948 2,474,816 Briggs July 5, 1949 2,507,022 Languepin May 9, 2,571,313 Tucker Oct 16, 1951 FOREIGN PATENTS Number Country Date 519,353 Great Britain Mar. 21, 1940 

